Modular processing channel for automatic processors

Abstract: Described herein is a low volume photographic material processing apparatus (10) which comprises a container (11) having a narrow horizontal processing channel (25). The channel (25) is formed by a repeating combination of rollers (22, 23) of a transport assembly (12, 13, 15) and includes a plurality of discharge openings through which photographic processing solution is introduced into the channel (25).

Description: Field of the Invention The invention relates to photographic processing apparatus and is more particularly concerned with a modular processing channel for such processors. Background of the Invention The processing of photosensitive material involves a series of steps such as developing, bleaching, fixing, washing, and drying. These steps lend themselves to mechanization by conveying a continuous web of film or cut sheets of film or photographic paper sequentially through a series of stations or tanks, each one containing a different processing liquid appropriate to the process step at that station. There are various sizes of photographic film processing apparatus, i.e., large photofinishing apparatus and microlabs. A large photofinishing apparatus utilizes rack and tank configurations which contain approximately 100 liters of each processing solution. A small photofinishing apparatus or microlab utilizes rack and tank configurations which may contain less than 10 liters of processing solution. The prior art suggests that if the volume of the various tanks contained within various sizes of photographic processing apparatus were reduced the same amount of film or photographic paper may be processed, while reducing the volume of photographic solution that was used and subsequently discarded. One of the problems in using smaller volume tanks is that the inner and outer sections of the tank typically are fixed and not separable. Another problem in using low volume tanks is that the material being processed typically has a tendency to jam. Hence, it was difficult and time-consuming to separate the rack from the tank for cleaning and maintenance purposes. One prior art low volume photographic material processing apparatus utilized photographic tanks having an inner rack section and an outer tank section which are easily separated. The processing apparatus contained a smaller volume of the same photographic solution than was previously used in regular-sized processing tanks. In fact, in some instances, the volume of photographic solution utilized in regular-sized tanks was reduced by as much as 90%. This apparatus permitted the inner rack section of the tank to be easily separated from the outer tank, while providing a narrow channel for both the photosensitive material and the processing solution. U.S. Patent 5,179,404 discloses a processing apparatus wherein a narrow processing channel is formed between a rack and a tank. The photosensitive material is transported through the narrow channel by appropriate rollers contained in the rack and tank. Problems to be solved by the Invention The prior art used automatic photoprocessing equipment to process photosensitive material. Automatic photoprocessing equipment typically is configured as a sequential arrangement of transport racks submerged in tanks filled with volumes of processing solutions. The shape and configuration of the racks and tanks are inappropriate in certain environments, for instance: offices, homes, computer areas, etc. The reason for the above is the potential damage to the equipment and the surroundings which may occur from spilled photographic processing solutions and the lack of facilities, i.e., running water and sinks to clean the racks and flush out the tanks. Photographic materials may become jammed in the processing equipment. In this situation the rack must be removed from the tank to gain access to the jammed photographic material in order to remove the jammed material. The shape and configuration of the racks and tanks made it difficult to remove a rack from a tank without spilling any processing solution. The prior art suggest that if the volume of the various tanks contained within various sizes of photographic processing apparatus were reduced the same amount of film or photographic paper may be processed, while reducing the volume of processing solution which was used and subsequently discarded. A problem in using low volume tanks is that the material being processed typically has a tendency to jam. An additional problem was that it was difficult and time-consuming to separate the rack from the tank for cleaning, for maintenance purposes and for removing jammed photosensitive material. A further problem was that processors are typically configured to handle photosensitive material in a roll format or a cut sheet format. A further problem with existing processors is that the processor may only process, at a given time, photosensitive material in a roll or cut sheet format. In addition, processors which are configured to process photosensitive material in a cut sheet format, may be limited in their ability to process the photosensitive material, by the minimum or maximum length of the photosensitive material, which may be transported. Additional rollers are required to transport shorter photosensitive material lengths. The reason for this is that, a portion of the photosensitive material must always be in physical contact with a pair of transporting rollers, or the cut sheet of photosensitive material will fail to move through the entire processor. As the number of required transport rollers increases, the size of the processing apparatus increases. A further problem with existing processors is that the processor may only be configured, at a given time, to process one variety of photosensitive material, i.e., photographic paper. Existing processors may not be readily configured to process X-ray film. Modularity has been sought after and not achieved in photographic processors. The photographic equipment industry has not heretofore provided a photographic processor that did not use completely different processing components, notwithstanding that modularity engenders efficiency in manufacturing, and also importantly provides the necessary flexibility to afford a photographic processor that meets different customer needs. Summary of the Invention This invention overcomes the disadvantages of the prior art by providing a low volume photographic material processing apparatus that utilizes a narrow horizontal processing channel with an upturned entrance and exit to contain the processing solution within the channel. In accordance with one aspect of the present invention, there is provided apparatus for processing photosensitive materials, the apparatus comprising:- at least one processing module each comprising a container, at least one processing assembly , said processing assembly having a processing channel formed therein through which a processing solution flows, the processing channel having an entrance through which the photosensitive material enters the processing solution and an exit through which the photosensitive material exits the processing solution, 100 times the thickness of the photosensitive material to be processed in the processing channel, each processing assembly having at least one discharge opening which delivers processing solution to the processing channel, the processing module further comprising transport means for transporting the photosensitive material from the channel entrance through the channel to the channel exit; and recirculating means for recirculating the processing solution through the small volume provided in the processing channel; characterized in that the processing channel comprises at least 40% of the total volume of processing solution available for the processing module; each processing assembly has at least one discharge opening which delivers processing solution to the processing channel. Preferably, the processing channel comprises at least 60% of the total volume of the processing solution for the processing module. The recirculating means comprises a pump for recirculating the processing solution, a plurality of conduits connected to the pump and the discharge openings for transporting the processing solution within the apparatus, and a filter connected to the pump for removing contaminants for the processing solution, the processing solution volume contained in the pump, conduits and the filter does not exceed the small volume for holding processing solution. Advantageously, each discharge opening has a configuration in accordance with the following relationship: .586 ≤ F A ≤ 23.4 wherein: F is the flow rate of the solution through the discharge opening in litres per minute; and A is the cross-sectional area of the discharge opening provided in centimetres squared. The channel is formed by a repeating combination of modular squeegee pinch rollers and modular impingement slot nozzles. The close, interdispersed arrangement of modular sets of squeegee pinch rollers and impingement slot nozzles form a contiguous thin, horizontal processing channel. Photographic processing solution is introduced into the channel through the modular impingement slot nozzles and the modular squeegee pinch rollers are used to transport the photosensitive material through the narrow channel. Solution level control is achieved by drains positioned below the tops of the upturned sections. Advantageous Effect of the Invention The above arrangement of modular squeegee pinch rollers and modular solution impingement slot nozzles, provide transport of either cut sheet or roll photosensitive material and work interactively to provide fresh processing solution to the photosensitive material while removing exhausted processing solution from the photosensitive material. The processing apparatus will contain a smaller volume of the same photographic solution than was previously used in regular-sized processing tanks. The modular squeegee pinch rollers and the modular solution impingement slot nozzles allow the processor to have many different configurations. The configurations may be readily changed, for instance the processor may be readily converted from a processor which processes photosensitive material in a paper format having an emulsion on one side to a processor which processes photosensitive material in which an emulsion is on both sides of the photosensitive material. This is accomplished by rearranging the modular slot nozzles to a configuration in which modular slot nozzles appear on both sides of the photosensitive material. The modular slot nozzles and modular rollers are configured such that each modular slot nozzle and each modular roller may be easily removed or inserted into a container which forms a continuous processor. This facilitates the servicing and cleaning of the processor and the repair of photosensitive material jams. The reason for the above is that only a single slot nozzle may have to be removed. The physical size of the processor is also reduced because the individual modular slot nozzles and modular rollers are utilized to form the channel. Since the slot nozzles and rollers are modular in format the number of component parts of the processor is less than conventional processors. It has been discovered, in accordance with the invention, that by utilizing a modular slot nozzle and modular rollers, the commonalty which supports modular design can be achieved. Brief Description of the Drawings For a better understanding of the present invention, reference will now be made, by way of example only, to the accompanying drawings in which:- Figure 1 is a perspective view of a processing module constructed in accordance with the present invention and which forms part of a tray processor; Figure 2 is a partially sectioned view of the module shown in Figure 1 illustrating one embodiment of a processing module according to the present invention for processing material having one emulsion surface; Figure 3 is a partially sectioned view similar to that shown in Figure 2, but of a second embodiment of a processing module according to the present invention; Figure 4 is a partially sectioned view similar to that shown in Figure 2, but of a third embodiment of a processing module according to the present invention for processing material having two emulsion surfaces; Figure 5 is a schematic view of a processing solution recirculation system of the apparatus in accordance with the present invention; Figure 6 is a partially sectioned perspective view of the processing module shown in Figure 1; Figure 7 is a schematic diagram showing the interconnection of a plurality of processing modules in accordance with the present invention to form a continuous photographic processor; and Figure 8 is a schematic diagram showing the integration of a plurality of processing modules in accordance with the present invention into a single body to form a continuous photographic processor. Detailed Description of the Invention Referring now to the drawings in detail, and more particularly to Figure 1, the reference character 10 represents a processing module, which may stand alone or be easily combined or adjoined with other processing modules 10 to form a continuous low volume unit for processing photosensitive materials. Processing module 10 includes: a container 11; an upturned entrance channel 100 (described with reference to Figure 2); an entry transport roller assembly 12; transport roller assemblies 13; an exit transport roller assembly 15; an upturned exit channel 101 (described with reference to Figure 2); high impingement slot nozzles 17a, 17b and 17c; a drive 16 and a rotating assembly 18, assembly 18 may be any known means for turning drive 16, i.e., a motor, a gear, a belt, a chain, etc. An access hole 61 is provided in container 11. Hole 61 is utilized for the interconnection of modules 10. Assemblies 12, 13 and 15 and slot nozzles 17a, 17b and 17c are positioned within the vicinity of the walls of container 11. Drive 16 is connected to roller assemblies 12, 13 and 15 and turning assembly 18 and assembly 16 is used to transmit the motion of assembly 18 to assemblies 12, 13 and 15. Roller assemblies 12, 13, and 15, and slot nozzles 17a, 17b and 17c may be easily inserted into or removed from container 11. Roller assembly 13 includes: a top roller 22; a bottom roller 23; tension springs 62; which holds top roller 22 in compression with respect to bottom roller 23; a bearing bracket 26; and a channel section 24 having a thin low volume processing channel 25. A narrow channel opening 27 exists within section 24. Opening 27 on the entrance side of section 24 may be the same size and shape as opening 25 on the exit side of section 24. Opening 27 on the entrance side of section 24 may also be relieved, tapered, radiused or larger than the exit side of section 24 to accommodate rigidity variations of various types of photosensitive material 21. Channel opening 27 forms a portion of processing channel 25. Rollers 22 and 23 may be drive or driven rollers and are connected to bracket 26. Rollers 22 and 23 are rotated by intermeshing gears 28. Photosensitive material 21 is transported in either direction A or direction B automatically through processing channel 25 by roller assemblies 12, 13 and 15. Photosensitive material 21 may be in a cut sheet or roll format or photosensitive material 21 may be simultaneously in a roll and simultaneously in a cut sheet format. Photosensitive material 21 may contain an emulsion on either or both of its surfaces. When cover 20 is placed on container 11 a light tight enclosure is formed. Thus, module 10 with its associated recirculation system 60, which is described with reference to Figure 5, will be a stand alone light tight module which is capable of processing photosensitive material, i.e., a monobath. When two or more modules 10 are combined a multi-stage continuous processing unit may be formed. The combination of one or more modules 10 will be more fully set forth in the description of Figure 7. Figure 2 is a partially sectioned view of the processing module 10 shown in Figure 1. Assemblies 12, 13 and 15, nozzles 17a, 17b and 17c and backing plate 9 are designed in a manner to minimize the amount of processing solution which is contained in processing channel 25, container 11, recirculation system 60 (Figure 5) and gaps 49a, 49b, 49c and 49d. At the entrance of module 10, an upturned channel 100 forms the entrance to processing channel 25. At the exit of module 10, an upturned channel 101 forms the exit to processing channel 25. Assembly 12 is similar to assembly 13. Assembly 12 includes: a top roller 30; a bottom roller 31; tension springs 62 (not shown) which holds top roller 30 to bottom roller 31; a bearing bracket 26; and a channel section 24. A portion of narrow processing channel 25 is formed by channel section 24. Rollers 30 and 31 may be drive or driven rollers and are connected to bracket 26. Assembly 15 is similar to assembly 13, except that assembly 15 has an additional two rollers 130 and 131, which operate in the same manner as rollers 32 and 33. Assembly 15 includes: a top roller 32; a bottom roller 33; tension springs 62 (not shown); a top roller 130; a bottom roller 131; a bearing bracket 26; and a channel section 24. A portion of narrow processing channel 25 exists within section 24. Channel section 24 forms a portion of processing channel 25. Rollers 32, 33, 130 and 131 may be drive or driven rollers and are connected to bracket 26. Backing plate 9 and slot nozzles 17a, 17b and 17c are affixed to container 11. The embodiment shown in Figure 2 will be used when photosensitive material 21 has an emulsion on one of its surfaces. The emulsion side of material 21 will face slot nozzles 17a, 17b and 17c. Material 21 enters channel 25 between rollers 30 and 31 and moves past backing plate 9 and nozzle 17a. Then material 21 moves between rollers 22 and 23 and moves past backing plates 9 and nozzles 17b and 17c. At this point material 21 will move between rollers 32 and 33, and move between rollers 130 and 131 and exit processing channel 25. Conduit 48a connects gap 49a, via port 44a to recirculation system 60 via port 44 (Figure 5), which is more fully described with reference to Figure 5, and conduit 48b connects gap 49b, via port 45a to recirculation system 60 via port 45 (Figure 5). Conduit 48c connects gap 49c, via port 46a to recirculation system 60 via port 46 (Figure 5) and conduit 48d connects gap 49d, via port 47a to recirculation system 60 via port 47 (Figure 5). Slot nozzle 17a is connected to recirculation system 60 via conduit 50a and inlet port 41a via port 44 (Figure 5) and slot nozzle 17b is connected to recirculation system 60 via conduit 50b and inlet port 42a via inlet port 42 (Figure 5). Conduit 50c connects nozzle 17c, via inlet port 43a to recirculation system 60 via port 43 (Figure 5). Sensor 52 is connected to container 11 and sensor 52 is used to maintain a processing solution level 235 relative to conduit 51. Excess processing solution may be removed by overflow conduit 51. Textured surface 200 is affixed to the surface of backing plate 9 which faces processing channel 25 and to the surface of slot nozzles 17a, 17b and 17c which faces processing channel 25. Figure 3 is a partially sectioned view of an alternate embodiment of module 10 of Figure 2 in which material 21 has an emulsion on one surface and nozzles 17d, 17e and 17f are on the top portion of container 11. Assemblies 12, 13 and 15, nozzles 17d, 17e and 17f and backing plate 9 are designed in a manner to minimize the amount of processing solution which is contained in processing channel 25 and gaps 49e, 49f, 49g and 49h. At the entrance of module 10, an upturned channel 100 forms the entrance to processing channel 25. At the exit of module 10, an upturned channel 101 forms the exit to processing channel 25. Assembly 12 is similar to assembly 13. Assembly 12 includes: a top roller 30; a bottom roller 31; tension springs 62 (not shown) which holds top roller 30 in compression with respect to bottom roller 31, a bearing bracket 26; and a channel section 24. A portion of narrow channel opening 25 exits within section 24. Channel section 24 forms a portion of processing channel 25. Rollers 30 and 31 may be drive or driven rollers and are connected to bracket 26. Assembly 15 is similar to assembly 13, except that assembly 15 has an additional two rollers 130 and 131 that operate in the same manner as rollers 32 and 33. Assembly 15 includes: a top roller 32; a bottom roller 33; a tension spring 62 (not shown); a top roller 130; a bottom roller 131; a bearing bracket 26; and a channel section 24. A portion of narrow processing channel 25 exits within section 24. Channel section 24 forms a portion of processing channel 25. Rollers 32, 33, 130 and 131 may be drive or driven rollers and are connected to bracket 26. Thus, it can be seen that a substantially continuous processing channel is provided. Backing plate 9 and slot nozzles 17d, 17e and 17f are affixed to container 11. The embodiment shown in Figure 3 will be used when photosensitive material 21 has an emulsion on one of its surfaces. The emulsion side of material 21 will face slot nozzles 17d, 17e and 17f. Material 21 enters channel 25 between rollers 30 and 31 and moves past backing plate 9 and nozzle 17d. Then material 21 moves between rollers 22 and 23 and moves past backing plates 9 and nozzles 17e and 17f. At this point material 21 will move between rollers 32 and 33 and move between rollers 130 and 131 and exit processing channel 25. Conduit 48e connects gap 49e, via port 44b to recirculation system 60 via port 44 (Figure 5) and conduit 48f connects gap 49f, via port 45b to recirculation system 60 via port 45 (Figure 5). Conduit 48g connects gap 49g, via port 46b to recirculation system 60 via port 46 (Figure 5) and conduit 48h connects gap 49h, via port 47b to recirculation system 60 via port 47 (Figure 5). Slot nozzle 17d is connected to recirculation system 60 via conduit 50d and inlet port 41b via inlet 41 (Figure 5) and slot nozzle 17e is connected to recirculation system 60 via conduit 50e and inlet port 42b via port 42 (Figure 5). Conduit 50f connects nozzle 17f, via inlet port 43b to recirculation system 60 via port 43 (Figure 5). Sensor 52 is connected to container 11 and sensor 52 is used to maintain a processing solution level 235 relative to conduit 51. Excess processing solution may be removed by overflow conduit 51. Textured surface 200 is affixed to the surface of backing plate 9 which faces processing channel 25 and to the surface of slot nozzles 17d, 17e and 17f which faces processing channel 25. Figure 4 is a partially sectioned vuew of an alternate embodiment of the processing module 10 shown in Figure 2 in which material 21 has an emulsion on both surfaces and nozzles 17g, 17h and 17i are on the top portion of container 11 facing one emulsion surface of material 21 and nozzles 17j, 17k, and 17L are on the bottom portion of container 11 facing the other emulsion surface of material 21. Assemblies 12, 13 and 15, nozzles 17g, 17h, 17i, 17j, 17k and 17L are designed in a manner to minimize the amount of processing solution that is contained in processing channel 25 and gaps 49i, 49j, 49k and 49L. At the entrance of module 10, an upturned channel 100 forms the entrance to processing channel 25. At the exit of module 10, an upturned channel 101 forms the exit to processing channel 25. Assembly 12 includes: a top roller 30; a bottom roller 31; tension springs 62 (not shown) which holds top roller 30 in compression with respect to bottom roller 31, a bearing bracket 26; and a channel section 24. A portion of narrow processing channel 25 exists within section 24. Channel section 24 forms a portion of processing channel 25. Rollers 30, 31 may be drive or driven rollers and are connected to bracket 26. Assembly 15 is similar to assembly 13, except that assembly 15 has an additional two rollers 130 and 131 which operate in the same manner as rollers 32 and 33. Assembly 15 includes: a top roller 32; a bottom roller 33; tension springs 62 (not shown); a top roller 130; a bottom roller 131; a bearing bracket 26; and a channel section 24. A portion of narrow processing channel 25 exists within section 24. Channel section 24 forms a portion of processing channel 25. Rollers 32, 33, 130 and 131 may be drive or driven rollers and are connected to bracket 26. Slot nozzles 17g, 17h and 17i are affixed to the upper portion of container 11. Slot nozzles 17j, 17k and 17L are affixed to the lower portion of container 11. The embodiment shown in Figure 4 will be used when photosensitive material 21 has an emulsion on both of its two surfaces. One emulsion side of material 21 will face slot nozzles 17g, 17h and 17i and the other emulsion side of material 21 will face slot nozzles 17j, 17k and 17L. Material 21 enters channel 25 between rollers 30 and 31 and moves past and nozzles 17g and 17j. Then material 21 moves between rollers 22 and 23 and moves past nozzles 17h, 17k, 17i and 17L. At this point material 21 will move between rollers 32 and 33 and move between rollers 130 and 131 and exit processing channel 25. Conduit 48i connects gap 49i, via port 44c to recirculation system 60 via port 44 (Figure 5) and conduit 48j connects gap 49k, via port 45c to recirculation system 60 via port 45 (Figure 5). Conduit 48k connects gap 49L, via port 46c to recirculation system 60 and conduit 48L connects gap 49j, via port 47c to recirculation system 60 via port 47 (Figure 5). Slot nozzle 17g is connected to recirculation system 60 via conduit 50g via port 41 (Figure 5). Slot nozzle 17h is connected to recirculation system 60 via conduit 50h and inlet port 62 via port 42 (Figure 5). Conduit 50i connects nozzle 17i, via inlet port 63 to recirculation system 60 via port 43 (Figure 5). Slot nozzle 17j is connected to recirculation system 60 via conduit 50j and inlet port 41c via port 41 (Figure 5) and slot nozzle 17k is connected to recirculation system 60 via conduit 50k and inlet port 42c via port 42 (Figure 5). Slot nozzle 17L is connected to recirculation system 60 via conduit 50L and inlet port 43c via port 43 (Figure 5). Sensor 52 is connected to container 11 and sensor 52 is used to maintain a level of processing solution relative to conduit 51. Excess processing solution may be removed by overflow conduit 51. Material 21 enters upturned channel entrance 100, then passes through channel section 24 of channel 25 between rollers 30 and 31 and moves past nozzles 17g and 17j. Then material 21 moves between rollers 22 and 23 and moves past nozzles 17h and 17k, 17L and 17i. At this point material 21 will move between rollers 32 and 33 and exit processing channel 25. Textured surface 200 is affixed to the surface of slot nozzles 17g, 17h, 17i, 17j, 17k and 17L which face processing channel 25. Preferred embodiments of slot nozzles 17a, 17b, 17c, 17d, 17e, 17f, 17g, 17h, 17i, 17j, 17k, 17L are described in European publication no. 0 623 848 published 09 November 1994 and entitled A Slot Impingement for an Automatic Tray Processor and European publication no. 0 623 847 published on 09 November 1994 entitled Counter Cross Flow for an Automatic Tray Processor. Figure 5 is a schematic drawing of the processing solution recirculation system of the apparatus of this invention. Module 10 is designed in a manner to minimize the volume of channel 25. The outlets 44, 45, 46 and 47 of module 10 are connected to recirculating pump 80 via conduit 85. Recirculating pump 80 is connected to channel 25 via conduit 4. Heat exchanger 86 is also connected to manifold 64 via conduit 63 and manifold 64 is coupled to filter 65 via conduit 66. Filter 65 is connected to heat exchanger 86 and heat exchanger 86 is connected to control logic 67 via wire 68. Control logic 67 is connected to heat exchanger 86 via wire 70 and sensor 52 is connected to control logic 67 via wire 71. Metering pumps 72, 73 and 74 are respectively connected to manifold 64 via conduits 75, 76 and 77. Thus, it can be seen that processing solution is pumped directly from the outlet passages to the inlet ports without use of a reservoir. The photographic processing chemicals which comprise the photographic solution are placed in metering pumps 72, 73 and 74. Pumps 72, 73 and 74 are used to place the correct amount of chemicals in manifold 64, when photosensitive material sensor 210 senses that material 21 (Figure 1) is entering the channel 25, sensor 210 transmits a signal to pumps 72, 73 and 74 via line 211 and control logic 67. Manifold 64 introduces the photographic processing solution into conduit 66. The photographic processing solution flows into filter 65 via conduit 66. Filter 65 removes contaminants and debris which may be contained in the photographic processing solution. After the photographic processing solution has been filtered, the solution enters heat exchanger 86. Sensor 52 senses the solution level and sensor 8 senses the temperature of the solution and respectively transmits the solution level and temperature of the solution to control logic 67 via wires 71 and 7. For example, control logic 67 is the series CN 310 solid state temperature controller manufactured by Omega Engineering, Inc. of 1 Omega Drive, Stamford, Connecticut 06907. Logic 67 compares the solution temperature sensed by sensor 8 and the temperature that exchanger 86 transmitted to logic 67 via wire 70. Logic 67 will inform exchanger 86 to add or remove heat from the solution. Thus, logic 67 and heat exchanger 86 modify the temperature of the solution and maintain the solution temperature at the desired level. Sensor 52 senses the solution level in channel 25 and transmits the sensed solution level to control logic 67 via wire 71. Logic 67 compares the solution level sensed by sensor 52 via wire 71 to the solution level set in logic 67. Logic 67 will inform pumps 72, 73 and 74 via wire 83 to add additional solution if the solution level is low. Once the solution level is at the desired set point control logic 67 will inform pumps 72, 73 and 74 to stop adding additional solution. Any excess solution may either be pumped out of module 10 or removed through level drain overflow 84 via conduit 81 into container 82. At this point the solution enters module 10 via inlets 41, 42 and 43. When module 10 contains too much solution the excess solution will be removed by overflow conduit 51, drain overflow 84 and conduit 81 and flow into reservoir 82. The solution level of reservoir 82 is monitored by sensor 212. Sensor 212 is connected to control logic 67 via line 213. When sensor 212 senses the presence of solution in reservoir 82, a signal is transmitted to logic 67 via line 213 and logic 67 enables pump 214. Thereupon pump 214 pumps solution into manifold 64. When sensor 212 does not sense the presence of solution, pump 214 is disabled by the signal transmitted via line 213 and logic 67. When solution in reservoir 82 reaches overflow 215, the solution will be transmitted through conduit 216 into reservoir 217. The remaining solution will circulate through channel 25 and reach outlet lines 44, 45, 46 and 47. Thereupon, the solution will pass from outlet lines 44, 45, 46 and 47 to conduit line 85 to recirculation pump 80. The photographic solution contained in the apparatus of this invention, when exposed to the photosensitive material, will reach a seasoned state more rapidly than prior art systems, because the volume of the photographic processing solution is less. Figure 6 is a partially sectioned perspective view similar to Figure 1. Processing module 10 includes: a container 11; an upturned entrance channel 100 (described with reference to Figure 2); an entry transport roller assembly 12; transport roller assemblies 13; an exit transport roller assembly 15; a upturned exit channel 101 (described with reference to Figure 2); high impingement slot nozzles 17a, 17b and 17c and backing plates 9. Assemblies 12, 13 and 15 are positioned within container 11 in the vicinity of the walls of container 11 and slot nozzles 17a, 17b and 17c are positioned within the vicinity of the walls of container 11. Roller assemblies 12, 13 and 15 backing plates 9 and slot nozzles 17a, 17b and 17c may be easily inserted into or removed from container 11. When roller assemblies 12, 13 and 15, backing plates 9 and slot nozzles 17a, 17b and 17c are inserted into container 11 a modular channel 25 is formed. Roller assembly 13 includes: a top roller 22; a bottom roller 23; tension springs 62, which holds top roller 22 in compression with respect to bottom roller 23; a bearing bracket 26; and a channel section 24. A narrow channel opening 25 exists within section 24. Opening 25 on the entrance side of section 24 may be the same size and shape as opening 25 on the exit side of section 24. Opening 25 on the entrance side of section 24 may also be relieved, tapered, radiused or larger than the exit side of section 24 to accommodate rigidity variations of various types of photosensitive material 21. Channel opening 25 forms a portion of processing channel 25. Rollers 22 and 23 may be drive or driven rollers and are connected to bracket 26. Photosensitive material 21 is transported in either direction A or direction B automatically through processing channel 25 by roller assemblies 12, 13 and 15. Photosensitive material 21 may be in a cut sheet or roll format or photosensitive material 21 may be simultaneously in a roll and simultaneously in a cut sheet format. Photosensitive material 21 may contain an emulsion on either or both of its surfaces. Figure 7 is shows the interconnection of a plurality of processing modules 10 to form a continuous photographic processor. Modules 10 may contain the same or similar processing solution to increase the productivity of the processor or perform different processing functions by containing different processing solutions. Any number of modules 10 may be interconnected, only three have been shown for illustrative purposes. Drive 16 (Figure 1) from each of the modules 10 is interconnected via drive access hole 61, by any known means, i.e., couplings, keyways, belts, chains, hex drives, etc. Modules 10 are physically connected to each other by any known mechanical fastening means, i.e., belts, screws, snaps, rivets, etc. Figure 8 shows the integration of a plurality of modules 10 into a single body 102 to form a continuous photographic processor, which contains more than one channel. Each module 10 may contain one or more roller assemblies and slot nozzles 17 to form a continuous photographic processor. Modules 10 may contain the same or similar processing solution to increase the productivity of the processor or perform different processing functions by containing different processing solutions. Any number of modules 10 may be interconnected, only three have been shown for illustrative purposes. Drive 16 (Figure 1) from each of the modules 10 is interconnected via drive access hole 61, by any known means, i.e., couplings, keyways, belts, chains, hex drives, etc. Modules 10 are physically connected to each other by any known mechanical fastening means, i.e., belts, screws, snaps, rivets, etc. A processor made in accordance with the present invention provides a small volume for holding processing solution. As a part of limiting the volume of the processing solution, a narrow processing channel is provided. The processing channel 25, for a processor used for photographic paper, should have a thickness t equal to or less than about 50 times the thickness of paper being processed, preferably the thickness t is equal to or less than about 10 times the paper thickness. In a processor for processing photographic film, the thickness t of the processing channel 25 should be equal to or less than about 100 times the thickness of photosensitive film, preferably, equal to or less than about 18 times the thickness of the photographic film. An example of a processor made in accordance with the present invention which processes paper having a thickness of about 0.2mm (0.008") would have a channel thickness t of about 2mm (0.080") and a processor which process film having a thickness of about 0.14mm (0.0055") would have a channel thickness t of about 2.54mm (0.10"). The total volume of the processing solution within the processing channel 25 and recirculation system 60 is relatively smaller as compared to prior art processors. In particular, the total amount of processing solution in the entire processing system for a particular module is such that the total volume in the processing channel 25 is at least 40% of the total volume of processing solution in the system. Preferably, the volume of the processing channel 25 is at least about 50% of the total volume of the processing solution in the system. In the particular embodiment illustrated, the volume of the processing channel is about 60% of total volume of the processing solution. Typically the amount of processing solution available in the system will vary on the size of the processor, that is, the amount of photosensitive material the processor is capable of processing. For example, a typical prior art microlab processor, a processor which processes up to about 0.46m 2 /min (5ft 2 /min) of photosensitive material (which generally has a transport speed less than about 1.27m/min (50" per minute) has about 17 liters of processing solution as compared to about 5 liters for a processor made in accordance with the present invention. With respect to typical prior art minilabs, a processor that processes from about 0.46m 2 /min (5ft 2 /min) to about 1.39m 2 /min (15ft 2 /min) of photosensitive material (which generally has a transport speed from about 1.27m/min (50in/min) to about 3.05m/min (120in/min)) has about 100 liters of processing solution as compared to about 10 liters for a processor made in accordance with the present invention. With respect to large prior art lab processors that process up to 4.6m 2 /min (50ft 2 /min) of photosensitive material (which generally have transport speeds of about 2.13 to 18m/min (7 to 60ft/min)) typically have from about 150 to 300 liters of processing solution as compared to a range of about 15 to 100 liters for a large processor made in accordance with the present invention. In a minilab size processor made in accordance with the present invention designed to process 1.39m 2 (15ft 2 ) of photosensitive material per minute would have about 7 liters of processing solution as compared to about 17 liters for a typical prior art processor. In certain situations it may be appropriate to provide a sump in the conduits 48a, 48b, 48c, 48d, 48e, 48f, 48g, 48h, 48i, 48j, 48k, 48L and/or gaps 49a, 49b, 49c, 49d, 49e, 49f, 49g, 49h, 49i, 49j, 49k, 49L so that vortexing of the processing solution will not occur. The size and configuration of the sump will, of course, be dependent upon the rate at which the processing solution is recirculated and the size of the connecting passages which form part of the recirculatory system. It is desirable to make the connecting passages as small as possible, yet, the smaller the size of the passages, for example, in the conduits 48a, 48b, 48c, 48d, 48e, 48f, 48g, 48h, 48i, 48j, 48k, 48L from the gaps 49a, 49b, 49c, 49d, 49e, 49f, 49g, 49h, 49i, 49j, 49k, 49L to the pump, the greater likelihood that vortexing may occur. For example, in a processor having a recirculatory rate of approximately 11.36 to 15.141/min (3 to 4 US gallons/min), there is preferably provided a sump such that a head pressure of approximately 100mm (4") at the exit of the tray to the recirculating pump can be maintained without causing vortexing. The sump need only be provided in a localized area adjacent the conduits 48a, 48b, 48c, 48d, 48e, 48f, 48g, 48h, 48i, 48j, 48k, 48L of the tray. Thus, it is important to try to balance the low amount of volume of the processing solution available to the flow rate required of the processor. In order to provide efficient flow of the processing solution through the nozzles into the processing channel, it is desirable that the nozzles/openings that deliver the processing solution to the processing channel have a configuration in accordance with the following relationship: .586 ≤ F A ≤ 23.4 wherein: F is the flow rate of the solution through the nozzle in litres per minute; and A is the cross-sectional area of the nozzle provided in centimetres squared. Providing a nozzle in accordance with the foregoing relationship assures appropriate of the processing solution against the photosensitive material. The above specification describes a new and improved apparatus for processing photosensitive materials. It is realized that the above description may indicate to those skilled in the art additional ways in which the principles of this invention may be used without departing from the claimed invention. It is, therefore, intended that this invention be limited only by the scope of the appended claims.

Claims: Apparatus for processing photosensitive materials (21), the apparatus comprising:- at least one processing module (10) each comprising a container (11), at least one processing assembly (9, 17a, 17b, 17c; 17d, 17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L) , said processing assembly having a processing channel (25) formed therein through which a processing solution flows, the processing channel (25) having an entrance (100) through which the photosensitive material enters the processing solution and an exit (101) through which the photosensitive material exits the processing solution, transport means (12, 13, 15) for transporting the photosensitive material (21) from the channel entrance (100) through the channel (25) to the channel exit (101); and recirculating means (64, 65, 80, 86, 226) for recirculating the processing solution through the small volume provided in the processing channel (25) ; characterized in that the processing channel (25) comprises at least 40% of the total volume of processing solution available for the processing module (10); each processing assembly (9, 17a, 17b, 17c; 17d,17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L) has at least one discharge opening (17a, 17b, 17c; 17d, 17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L) which delivers processing solution to the processing channel (25). Apparatus according to claim 1, wherein the processing channel (25) comprises at least 60% of the total volume of the processing solution for the processing module (10). Apparatus according to claim 1 or claim 2, wherein the recirculating means (64, 65, 80, 86, 226) comprises a pump (80) for recirculating the processing solution, a plurality of conduits (41, 42, 43, 44, 45, 46, 47, 63, 85) connected to the pump (80) and the discharge openings (17a, 17b, 17c; 17d, 17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L) for transporting the processing solution within the apparatus, and a filter (65) connected to the pump (80) for removing contaminants for the processing solution, the processing solution volume contained in the pump (80), conduits (41, 42, 43, 44, 45, 46, 47, 63, 85) and the filter (65) does not exceed the volume of the processing channel (25). Apparatus according to any one of the preceding claims, wherein the transport means (12, 13, 15) comprises a plurality of rollers (22, 23; 30, 31; 32, 33; 130, 131) each pair of rollers (22, 23; 30, 31; 32, 33; 130, 131) having a portion of the processing channel (25) formed therebetween. Apparatus according to claim 4, wherein each discharge opening (17a, 17b, 17c; 17d, 17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L) has a configuration in accordance with the following relationship: .586 ≤ F A ≤ 23.4 wherein: F is the flow rate of the solution through the discharge opening (17a, 17b, 17c; 17d, 17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L) in litres per second; and A is the cross-sectional area of the discharge opening (17a, 17b, 17c; 17d, 17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L) provided in square metres. Apparatus according to any one of-the preceding claims, wherein the transport means (12,13, 15) are disposed adjacent each processing assembly (9,17a, 17b, 17c; 17d, 17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L). Apparatus according to claim 6, wherein the transport means (12, 13, 15) forms a substantially continuous processing channel (25) through which a processing solution flows. Apparatus according to any one of the preceding claims, further including at least one outlet (48a, 48b, 48c; 48d, 48e, 48f; 48g, 48h, 48i; 48j, 48k, 48L) for allowing processing solution to exit the processing channel (25), the recirculating means (64, 65, 80, 86, 226) recirculating the processing solution from each outlet (48a, 48b, 48c; 48d, 48e, 48f; 48g, 48h, 48i; 48j, 48k, 48L) directly to each discharge opening (17a, 17b, 17c; 17d, 17e, 17f; 17g, 17h, 17i; 17j, 17k, 17L). Apparatus according to any one of the preceding claims, wherein the processing assembly (9,17a,17b,17c,17d,17e,17f,17g,17h,17i,17j,17k,171) is removably mounted in the processing module (10), and the processing channel (25) is formed in the processing assembly. Apparatus according to any one of the preceding claims, wherein the thickness of the processing channel is about 2.Omm, preferably for use with photosensitive paper material (21), or is about 2.54mm, preferably for use with photosensitive film material (21).

Inventors: MANICO JOSEPH ANTHONY, PATTON DAVID LYNN, PICCININO RALPH LEONARD, ROSENBURGH JOHN HOWARD, MANICO, JOSEPH ANTHONY, PATTON, DAVID LYNN, PICCININO, RALPH LEONARD, ROSENBURGH, JOHN HOWARD, MANICO, JOSEPH ANTHONY, C/O EASTMAN KODAK COMPANY, PATTON, DAVID LYNN, C/O EASTMAN KODAK COMPANY, PICCININO, RALPH LEONARD, C/O EASTMAN KODAK CO., ROSENBURGH, JOHN HOWARD, C/O EASTMAN KODAK COMPANY
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY
Application year: 1994
Main classification: G03D3
IPC codes: G03D3, G03D5